Matthew — Director OF Manufacturing

Honeywell Intelligrated - West Chester, OH December 2016 to Present - I introduced Robotics and Automation into a low volume manufacturing facility. By doing so, I could improve the lean manufacturing process to save $2 million dollars per year. By writing new lean processes and utilizing six sigma, and 5S in the cells to help ease the work load of operators and create a visual and functional work cell. I have completed three Robotic cells in my time at Honeywell. Reporting to the Director of Manufacturing, I brought new lean based suppliers into the companies supply chain. Using the new suppliers, I was able to improve first time yield on new cells, and be able to quote suppliers that new how to design and build to the SOW. - Working with lean manufacturing principles, 5S, and a team concept, I brought in these three cells at or under budget, on time, with an increased first time yield. The quality of the product was also improved by having the lean process followed on each part, or assembly. I also wrote the RFQ's, Capex, SOW, did vendor selection, wrote the new lean processes, time studies, selected and worked with suppliers to be on time and on budget. Working with purchasing, The next Robotic Weld Cell with cut 3 hours off each assembly. With a rate of 9600 assemblies per year, this will translate into a savings of over a 1 million dollars per year. Quality Improvement Engineer General Electric Appliances - Louisville, KY

1997 to July 2003 - Metal Forming Equipment, Rivet & Weld Lines, Pierce Stations, Jig & Fixture, Special Machines, and Material Handling Equipment - Responsible for tool content, budgets, schedule, and progress. - I was also lead for 25 to 28 Catia design engineers. - Concept, design, layout, and detailing of automotive rollform & hemmer equipment and presses, robot end effectors, transfer equipment, heavy truck rivet cells, body side & under body weld systems, under body pierce stations, fixture and special machine design. Program kickoff, setup & conducting formal customer design reviews, & change management. Follow up with customer and build shops to ensure cost, timing, and quality are met as required. All work in SolidE or advanced surfacing to Chrysler, GM and Freightliner modeling and design standards. Catia Design Supervisor & Catia Data Manager Odyssey Inc - Oxford, MI

1987 to January 1991 Tooling Design and Fabrication Representative - Responsible for directing and coordinating supplier tool designs, tool manufacturing, and quality from concept through production tryout. - Also budget, delivery, and program status. All work in advanced surfacing and wireframe. Worked AV-8B Harrier, YF-23, A-12, C-17, and F-22 composite tooling. Secret security clearance

July 2015 to December 2016 - I introduced visual checks into a dishwasher rack assembly line. The parts were manually loaded and would be missing wires or have the wires miss-located. The check was done directly before welding, and would route bad wire layups back for rework. - The vision system was carried into four cells total, and was responsible for cutting scrap from $7000 per day to $2000 per day. This was a huge cost savings for the company. I had chosen and worked with the supplier to incorporate the vision systems into production. This also included writing new process sheets for the jobs. We have been under operating plan budget since the first month of the year and each month thereafter. I planned 3 months out past the existing month to show progress and have projects that are true contributors for the company. Sr. Die Improvement Engineer Toyotomi America - Springfield, KY

January 2014 to July 2015 - As a Senior Die Improvement Engineer I was responsible for improving production throughput of the dies for production parts. This included help in setting up a PM schedule for die sharpening and repairs, tryout of new dies, changeover of dies for new equipment fitment, and working within the Toyota Production System. Toyotomi is a Tier 1 supplier to Toyota. Sr. Lead Manufacturing Engineer General Electric Aviation, Evandale, Oh

May 2011 to December 2013 Design Manual, and Automation Lines for Robotic Welding, Assembly, & Painting, De-Burring and Inspection

May 2011 to December 2013 - By designing cells utilizing lean principles, I was able to introduce a new robotic cell for drilling 1800 close tolerance GD&T True Position holes in an aircraft assembly. I also used the same cell to do 100% inspection while drilling. This was accomplished by pairing the robot with a Laser Tracker system. The laser tracker positioned the robot in a world coordinate system, and a printer recorded the true XYZ position of the robot. The quality report was printed and using black ink for passed hole locations, and red ink for out of tolerance locations, quality could readily conclude if the assembly was good. By drilling and checking simultaneously - I was able to save 45 hours on manufacturing cost per assembly. This translated into a savings of over $13 million dollars per year on a three year fixed price contract. - Utilizing the lean principles, I created cells to do Deburr, an automated paint line with limited material handling, and an overhead powered rail robot drilling station. - I also concepted all tooling requirements for outside supplier design / build for the automation cells. Process, timing and sequence of operations for new manual, and automated production to improve first time yield, cost reductions and throughput. Lead ad-hoc teams in different manufacturing facilities to drive lean processes, automation, robot programming, and integration. I design of a complete automated paint line for a new facility in Mississippi. Included in the design are power & free conveyor systems, lean parts flow and limited material handling. Develop SOW and Buy Specifications, vendor selection, support, and integration. Application submitted for patent of a new robotic assembly process. The patent application was submitted in February of 2012, ten months after being employed by GE Aviation. Authored a handbook entitled "Transition to Production." The manual defined how to prove tooling will support the lean manufacturing production process before Start of Production (SOP,) and begin implementing 5S, Six Sigma, and continuous quality improvement immediately. Manager, Manufacturing Engineering BAE Systems - Fairfield, OH

February 2009 to May 2011 Design Production Lines for Government and Armored Vehicles, Process Development

February 2009 to May 2011 - Responsible for launch of new programs, creating new and optimizing existing production processes for cost reduction and improved quality. I was also responsible for 18 manufacturing engineers, 2 robot programmers, and a 325,000 sq. ft. manufacturing facility. - Implemented standardized launch criteria for new programs that included manufacturing and quality plans. Drive lean Manufacturing Principals, Kaizen Events, 5S, and comprehensive PM (preventative maintenance) schedules for tooling and fixtures to begin at program start-up. Planned with maintenance to order and maintain spare tool & fixture parts to limit production downtime. - Provided ME's with a Continuous Quality Improvement atmosphere that focuses on process improvement, and cost reduction throughout the life of the program. - Quoting and business case development for CAPEX expenditures to support new program launches, capital equipment, and production start-up costs. Creation of an Excel spreadsheet to record standardized work times, sequence of operations and timing. - IPT Team reviews of Product Designs for DFM, and DFA, Tool Designs, and Quality Plans to ensure adherence to PPAP, DFMEA, PFMEA, guidelines and requirements. - I introduced use of a new Laser Tracker for inspection, set-up of production tooling, and tool calibration. - Designed and implemented fully automated robotic weld cells to mig weld BIW armored truck cabs. These process improvements led to a productivity increase that reduced build time by 35 hours per unit for 4400 total units. Worked with product engineering groups to redesign armored cab panels and reduced number of panels from 10 panels to 5 panels. The redesign also saw a reduction of 2000 inches of mig weld, and resulted in a cost savings of $589.00 per unit for 4500 cabs. I created program files with samples and templates to standardize Manufacturing Engineering Program data for use on the shop floor. Also set-up mandatory training classes on the BAE L&D Training Network. This is used to provide continuous educational improvement for the employees, while making them a more valuable asset to the company. Engineering Manager Edag Productions LLC - Auburn Hills, MI

August 2003 to January 2009 Designed Tomcar Off-road Vehicle Production Line, Supplier Development, Product Development, New Program Launch, and Business Development. - Responsible for quoting and business case development for new product designs, launches, lean manufacturing process, production line designs, and timing through put. - Designed and implemented production line to build complete Tomcar Off Road Side x Side vehicle. I worked with suppliers in USA to manufacture a newly designed wiring harness, MIG welded frames (3) styles, and other complex vehicle components for high quality with competitive pricing. - Working extensively with suppliers in Taiwan, China, and the USA to supply parts and assemblies of high quality and low price. The following new products included front and rear coil over shocks, aluminum three and four core radiators, a complete exhaust system with catalytic converter, a new rack and pinion assembly, aluminum wheels, steel gas tanks, and miscellaneous machined components. - Cost saving benefits of $20 million dollars over a five year period achieved utilizing Asian suppliers. - Set-up spare part program, and warranty programs with all overseas, and U.S. suppliers. - I provided engineering support and direction for EPA certification programs, also various water, air quality, and hazardous waste disposal compliance testing and government, state, or city permits. Product & tooling design reviews, also working with quality engineers to support PPAP, and DFMEA requirements. Managed up to 45 employees in different disciplines. Catia Design Supervisor J.S. McNamara Inc - Warren, MI June

October 1995 to June 1997 - Design Supervisor of (7) Catia Design Engineers - Responsible for tool content, budgets, schedule, progress. Also lead 7 Catia design engineers, and 3 N/C programmers. Concept, design, layout, and detail of weld fixtures, drill & assembly jigs, N/C mill fixtures, special machines, and bond tools. Formal customer design reviews, change management, and follow up with customer and build shops. All work in SolidE or advanced surfacing to customer modeling and design standards. Senior Lead Catia Design Eng Modern Engineering Inc. Troy, Mi

August 1994 to October 1995 - Responsible for designing and directing team of ten tool design engineers from concept through production of invar steel bond tools for carbon epoxy production parts, and five axis milling fixtures. All work in solids and advanced surfacing. Senior Lead Design Engineer M & T Design Services Inc - Madison Hts, MI

October 1992 to August 1994 Product Designer - Design of chassis components for Chrysler programs to include shock towers, trailing arm assemblies, cross member supports, etc. All designs utilized Catia advanced surfacing, wireframe, and draw for prototype release to production. - Senior Design Lead FSX Fighter Program of bond tooling for carbon epoxy parts. - Internal Product Team member at Boeing for 777 Strut & Nacelle tooling program. - Responsible for designing and directing team of (5) tool design engineers for large assembly jigs, large bond tools for carbon epoxy parts, and final assembly trim tools utilizing Catia solids, advanced surfacing and draw to produce drawings for full production release. Tool fabrication shop support for fabrication, quality, and cost reduction solutions. All work in solids and advanced surfacing. Senior Project Manager Boeing Commercial Aircraft - Seattle, WA May 1991 to October 1992 Senior Project Manager, Tool Design Offload - Responsible for directing and coordinating supplier tooling from concept and design to quality concerns from production. - Conducting tooling and manufacturing surveys, directing/ monitoring the design build process for improvements to scheduling and cost reduction. Tooling types included floor assembly jigs, scaffolding and material handling equipment. All work in solids and advanced surfacing. Tool Design Engineer, Fabrication Representative to Tooling Suppliers McDonnell Douglas Aircraft Co - St. Louis, MO September